System and method for the concentration of a slurry

ABSTRACT

The present invention relates to a system and a method for the concentration of slurry, especially mineral containing slurry. The invention provides a system comprising an electrophoresis unit and a separation unit, where the separation unit comprises a recipient, preferably of half cylindrical form, with adjusted flanks for separating the solid material or cake from the rotating anodes and a sliding carriage suitable for closing the recipient and stripping resting solid material from the flanks into the recipient before the solid material or cake is pressed out of the recipient by a piston.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a Divisional of U.S. application Ser. No. 13/641,755, filed Dec.21, 2012, which is the U.S. national phase of PCT Application No.PCT/EP2011/056728, filed Apr. 28, 2011, which claims priority toEuropean Application No. 10161498.0, filed Apr. 29, 2010 and U.S.Provisional Application No. 61/331,951, filed May 6, 2010, the contentsof which are hereby incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to a system and a method for theconcentration of slurry, especially mineral containing slurry.

BACKGROUND OF THE INVENTION

Mineral processing often requires the addition of water. This may resultin an overly dilute slurry containing the mineral so that it isnecessary to concentrate the finely granulated minerals of thesuspension for further processing. Depending on the required finalconcentration of the mineral, different methods are used for thedewatering process. Besides methods like centrifugation, filtration orevaporation it is known that the dewatering of slurries can be achievedby electrophoresis or electroosmosis leading to the formation of a solidlayer or cake.

U.S. Pat. No. 1,133,967 discloses an apparatus for an electroosmoticprocess having a suspension container and suspension agitating means,which comprise an anode and a cathode locked between the anode and theagitating means, where the cathode is provided with openings of muchgreater length than width. The anode according to this invention iscylindrical.

U.S. Pat. No. 3,972,799 describes an apparatus for removing solids fromdrilling mud. The apparatus comprises a horizontal container with aplurality of spaced-apart rotating plate-like discs as anodes arrangedbetween pluralities of spaced-apart interconnected panels as cathodeswith a peripheral portion of each disc immersed in the drilling mud,where the discs are rotated by a motor. Solids in suspension areattracted by and deposited as a layer or film on opposing surfaces ofthe respective discs and stationary scraper blade elements arrangedadjacent to the discs remove the deposited solids.

To achieve the exposure of a solid layer or cake from a suspension,rotating anodic discs are proposed by U.S. Pat. No. 4,107,026 thatdiscloses a system and a method for dewatering of a suspension of solidsin an electric field controllably maintained between a pair of opposingself-contained electrode structures, to cause the solids to migraterelatively to the carrier liquid to form a layer or cake on therespective self-contained electrode structure, while allowing carrierliquid to be withdrawn under vacuum in the opposite direction throughthe liquid-pervious wall of a hollow self-contained counter electrodestructure, combined with means for controlling the rate of filtrateliquid withdrawal consistent and compatible with the relative speed ofmigration of the solids in the carrier liquid and wherein said layer orcake material may be detached from said electrode structure, forinstance during exposure from the suspension.

In order to increase the efficiency of electrophoretic separation, U.S.Pat. No. 5,171,409 (the equivalent of EP 0 253 749) proposes a processof continuously separating electrically charged, solid pulverousmaterials in the form of a suspension in an electrophoresis andelectroosmosis cell, wherein a fraction of the catholyte is drained off,a portion thereof is treated with an acid, preferably gaseous, agent,the treated portion is re-introduced into the cathode compartment,whereas the other part of the drained-off fraction is eliminated. As themethod and device disclosed in this document are very complicated tohandle, there is a need for a device that is easy to handle incombination with a high rate of yield.

Although the processes of dewatering suspensions by electrophoresis orelectroosmosis are known in the state of the art, both methods areassociated with a dissatisfactory degree of mineral cake or solidrecovery, especially in the case of calcium carbonate recovery in theform of a sticky mineral cake or solid.

DESCRIPTION OF THE INVENTION

It is an object of the present invention to provide a system and amethod for the concentration of slurry containing minerals, avoiding thedisadvantages of known systems and methods.

According to the invention a device is provided for the concentration ofa slurry, with a supporting structure for receiving modules therein, themodules comprising:

-   -   a. an electrophoresis cell with at least one electrically        connected cathode, and at least one electrically connected,        rotatable anode disc,    -   b. separation units adjacent to each anode surface for receiving        the cake material, comprising a recipient and a piston, wherein        the shoulders of the recipient are dimensioned to act as        scraping flanges for taking off the solid material or cake from        the anodes and the piston for pressing the collected material or        cake out of recipient, and optionally a sliding carriage with a        cover for closing the recipient, and    -   c. means for turning the anodes, circulating slurry in and out        of the electrophoresis cell, and applying voltage to the        electrodes

The electrophoresis cell may be a container for taking up the slurry,designed to include a single or multiple-compartments forelectrophoresis. In the preferred embodiment where the electrophoresiscell is a multiple-compartment cell, this may be formed by weldingplates into the container, so that the multiple-compartment container ismade from an outer container shell with flanges fixed inside thecontainer to form the compartments. In a further preferred embodiment,the multi-compartment slurry container is a single integral piece.

Although it is intended that the whole container, including amulti-compartment container, functions as cathode, it is also within thescope of the invention that the cathode is represented by one or moreplates or other means positioned in the electrophoresis cell. If theelectrophoresis cell or container is the cathode, no separate linkage tothe power supply is necessary and the (multi) compartment slurrycontainer is electrically isolated from all other components.

It is intended that the anode discs be partially exposed to the slurryand partially exposed to a gaseous environment such as air. It isfurther intended that the shoulders of separation units be locatedadjacent to a portion of anode exposed to a gaseous environment. It ispreferred that the separation units be located in an approximatelyhorizontal position.

It is preferred that the anode discs are arranged vertically within agiven compartment. In order to rotate the anode discs, they arepreferably mounted on a drive shaft for rotation. Further the anodediscs can be fixed on the drive shaft by means of fixation flanges,defining the distance between the anode discs. The anodes respectivelythe anode discs are electrically connected by jumper rings that areprovided.

If it is necessary, due to a special composition of slurry, alteredcontainer and altered anode disc spacing can be used. In a preferredembodiment, the outer wall of the container is half cylindrical andadjusted to the diameter of the anodes to produce a predefined distancebetween cathode and anode discs. The half cylindrical container designfacilitates the requirement that the anodes are only partially exposedto the slurry.

In another preferred embodiment, at least one inlet opening for theslurry is positioned at the bottom of each electrophoresis cell and anoverflow at the upper margin. In an alternative embodiment the inletopenings can be distributed over the circumference of each cell.

The preferred material for the anodes is titanium with an anticorrosivecoating. For positioning of the anodes, muffs may be used to ensure anappropriate distance is maintained between the cathode(s) and anodes,said distance being critical for the dewatering process. Alternatingmuffs and anode discs can form a unit that is slid onto the shaft. It isalso important that the distance between the anode disc and theseparation unit be constant. Cross sectional areas of the muffs may beused to guarantee that the anode discs cannot move on the shaft.

The jumper ring can be made with gold contacts so that higher voltagesare possible in up scaled systems. The contacts are preferably elastic.

For the supporting frame, the preferred material is aluminium. Thisframe represents the backbone of the system and all other parts areattached to this frame. Plates of synthetic material can be used toisolate the supporting frame from the container when the latterrepresents the cathode. Further plates may be used as support for theanode unit and the motor for rotating the anode respectively the shaft.

The preferred form of the recipient of the separation unit is halfcylindrical or half rectangular with a piston adapted to the recipientform. It is obvious for a person skilled in the art that other forms mayapply to the recipient. The separation unit is preferably made ofsynthetic material, especially poly-tetra-fluoroethylene (PTFE) or anyother material with good sliding properties. Since the shoulders of thehalf cylinder are adjusted to the adjacent anode discs there is no needfor a separate scraper. This has the major advantage that solid materialor cake will not be collected on the scraper. In combination with thesliding carriage for closing the separation unit, the solid materialwill be completely pressed out of the separation unit. An open halfcylinder, i.e. without a sliding door, resulted in experiments of theinventors in solid material that has been accumulated on the scraper andthe piston resulting in an incomplete removal of the solid material orcake.

The separation unit is ideally exactly positioned between two anodediscs, such that the separation unit may serve to remove cake from twoanode discs simultaneously. The resting opening between separation unitand anode is preferably about 1 mm. The separation unit may be fixed bysynthetic mountings at the supporting frame.

By making piston and half cylinder from the same material, anydisadvantages according to different thermal expansion are avoided.

It is preferred that the piston be driven pneumatically. Any other meansfor driving the piston, e.g. hydraulically, are also within the scope ofthe invention.

Since the process for the concentration of slurry is preferably drivendiscontinuously, the angle of rotation of the anodes in each cycle shallbe preferably about 10° in combination with a preferred length of stayof the anode segments of about 3 min.

In a preferred embodiment, a voltage between 10 V and 40 V is applied tothe electrodes. The voltage depends on the material forming theelectrodes and the composition of the slurry. It should be limited withregard to corrosion of the anode and thus not be above 60 V.

The device according to the invention is optimized for slurry that has amineral content of preferably between 10-50% and more preferably between20-24% and a defined particle size. Parameters such as voltage can beadjusted to other slurries without changing the distance between theelectrodes as this is predetermined by the construction of anelectrophoresis cell.

The preferred material to be used in the device is slurry containingnegatively-dispersed calcium carbonate particles.

Another object of the present invention is a method for theconcentration of a slurry using a device according to the inventioncomprising the following steps:

-   -   a. Introducing a slurry with dispersed particles in the        electrophoresis cell of said device;    -   b. Applying voltage to the resting electrodes of the        electrophoresis cell;    -   c. Rotating each anode a defined angle of rotation and stripping        resting solid material or cake into the recipient of the        separation unit of said device;    -   d. Optionally closing said recipient with a sliding carriage;    -   e. Pressing the solid material or cake out of the separation        unit with a piston;    -   f. Optionally introducing fresh slurry into the electrophoresis        cell via the inlet opening and removing excess slurry via the        outlet of each cell and repeating steps a to f.

It is preferred that the concentration process be drivendiscontinuously, implying a step of the anode resting in the slurry anda step of the anode being rotated in order to receive the solid materialor cake, in order to be able to remove the material efficiently.

The method is optimized for slurries containing mineral particles,especially calcium carbonate and notably negatively-dispersed calciumcarbonate. Cationically dispersed calcium carbonate may additionally oralternatively be employed.

To optimize the stability of the solution and the charge of theparticles it is preferred that tensides, such as dispersants, be addedto the slurry. As the tensides become attached to the particles, theresulting charge corresponds to the charge of the tenside. In this wayit is possible to enhance or change the charge of the dispersed particleso that they will move to the anode or cathode as required.

The optimal parameters for the method are a voltage of about 20 V and anangle of rotation of about 10°, where hoist time and interval time canbe adjusted to characteristics of the slurry. Preferred is a length ofstay of the anode disc of about 3 min.

The process of cake collection, i.e. the anode rotation, is interruptedwhile the piston is fully extended. The piston has to be drawn backbefore the anode can rotate again to avoid the collection of cake behindthe piston leading to problems at the draw back of the piston.

DETAILED DESCRIPTION OF THE FIGURES

The invention will be further described by figures and examples withoutbeing limited to the described embodiments:

FIG. 1 Plot of the solid content of the deposition cake against thevoltage applied to the electrodes

FIG. 2 Plot of the specific deposition rate against the voltage appliedto the electrodes

FIG. 3 Plot of the specific energy consumption against the voltageapplied to the electrodes

FIG. 4 Plot of the solid content of the deposition cake against thedistance of the electrodes

FIG. 5 Plot of the specific deposition rate against the distance of theelectrodes

FIG. 6 Plot of the specific energy consumption against the distance ofthe electrodes

FIG. 7 Plot of the solid content depending on the retention time

FIG. 8 Plot of the specific deposition rate depending on the retentiontime

FIG. 9 Plot of the specific energy consumption depending on theretention time

FIG. 10 Separation unit

FIG. 11 A, B: Arrangement of the separation units and anode discs

FIG. 12 Electrophoresis cell with inlet and overflow

FIG. 1 shows that the voltage applied to the electrodes has aconsiderable influence on the solid content of the deposition cake resp.the osmosis. Solid content and deposition rate (FIG. 2) increase withraising the voltage, but the energy consumption (FIG. 3) increasesdisproportionally. The reason for this effect is an increase inelectrolysis of the contained water. It is a serious problem that theelectrophoresis of the water content leads to the production of hydrogenand oxygen, which form an explosive mixture with the surrounding air. Itis not possible to reduce the voltage to a level that no hydrogen isproduced.

Consequently, a compromise had to be determined allowing a goodproductivity with reasonable energy consumption. Most experiments weredone with a voltage of 20 V, although the voltage might range from 10 to60 V.

Further experiments were performed in order to determine a distance ofthe electrodes with regard to the solid content (FIG. 4), specificdeposition rate (FIG. 5) and the specific energy consumption (FIG. 6).The distance of the electrodes can usually only be changed with animmense effort, e.g. with movable cathodes, so that it is import to knowan optimal distance of the electrodes for the construction of anelectrophoresis device.

The results shown in FIGS. 4 to 6 were obtained by applying a voltage of20 V. It is clearly visible that a short distance of the electrodescorrelates with an increase of efficiency of the electrophoresis, viz.solid content and deposition rate increase with a decrease of energyconsumption. This means that a short distance of electrodes has to bepreferred.

It has to be taken into account that the deposition cake on the anodereduces the opening between cathode and anode. The experiments showed aphysical thickness of the anode cake of about up to 10 mm. It has to beguaranteed that the residual opening between the electrodes is suitablefor the flow through of the slurry. In FIG. 5 a stagnation of thedeposition rate can be observed for a distance of electrodes above 20mm. This might reflect the effect of minimizing the opening between theelectrodes by the anode cake.

By using rotating anodes different modes of performing theelectrophoresis can be applied. The anodes can rotate continuously or inintervals. The increasing anode cake on the anode disc 50 leads to anincrease of the electrical resistance as the solid cake has a higherelectrical resistance than the slurry. As a consequence the depositionrate decreases (FIG. 8) and the energy consumption increases (FIG. 9),while the solid content of the anode cake still increases (FIG. 7).

The results of the experiments for determining a reasonable retentiontime as shown in FIGS. 7 to 9 were performed with a voltage of 20 V, anelectrode distance of 40 mm and an angle of rotation of 45°.

Angle of rotation and retention time are important parameter with regardto the total amount of anode cake deposited on the anode disc 50. Thevolume of the anode cake has to correlate with the volume of theseparation unit in order to avoid overfilling of the separation unit, asthis would lead to remaining solid particles on the anode disc 50. Theskilled man would adapt the degree of rotation according to thethickness of the cake on the anode, i.e. the thicker the cake is, thesmaller the degree of rotation of the anode before the recipient 40 isfilled.

Some restrictions have to be taken into account while defining theparameters for the construction of the device and performing theelectrophoresis. Applying high voltage to the electrodes should beavoided since the side effect of hydrogen production has to be reducedfor safety reasons. The distance of electrodes is basically predefinedby the concept of the multi compartment slurry container 60 as shown inFIG. 11. The remaining parameters have to be chosen in order to optimizesolid content of the anode cake and obtain a high deposition rate.

Table 1 shows the parameters that have been chosen for a deviceaccording to the invention.

Starting spec. parameter solid deposition spec. energy (preferredcontent rate consumption parameter) (%) F_(FS) (^(kg)/_(m) ² _(h))F_(AR) (^(kWh)/_(t)) F_(EV) U = 20 V 42.3 29.4 49.9 H = 40.0 mm 41.51,000 31.1 1.045 42.2 0.988 (H = 37.5 mm)* (41.5) (32.5) (41.7) t_(v) =4 min 42.5 0.988 27.0 1.056 52.8 0.985 (t_(v) = 3 min)* (42.0) (28.5)(52.0) α = 45° 38.9 1.131 19.7 1.131 46.7 0.642 (α = 10°)* (44.0) (24.0)(30.0) Preferred 47.3 39.5 31.2 operating cond.

Values not corresponding exactly to measured values have beenextrapolated according to the curve progression (*). Starting point forthe calculation has been taken from the results obtained for thevariation of the voltage, shown in the top line of table 1. The changesof solid content, deposition rate and energy consumption were taken fromexperiments varying electrode voltage, retention time and angle ofrotation. Using the preferred parameters in preferred operatingconditions, results in the solid content, deposition rate and energyconsumption shown in the line at the bottom. The voltage should beadjusted to 20 V and the electrode distance H chosen according to theconstruction of the slurry container 60. The retention time should beabout 4 min and the angle of rotation 45° in order to optimize solidcontent, deposition rate and energy consumption.

FIG. 10 shows a separation unit that comprises a recipient 40 forreceiving the cake material from a rotating anode 50. The shoulders 30of the recipient 40 are dimensioned to act as scraping flange for takingoff the solid material or cake from the anodes 50. Collected materialwill be pressed out of the recipient 40 by a piston 20 which is drivenby a pneumatic cylinder 21 that is regulated through valves 22. It isintended that the recipient could be closed with a sliding carriage 10.The sliding carriage 10 comprises a cover 11 and guiding rods 12.

It is further intended that the sliding carriage 10 for closing therecipient 40 has a wiper at the front, for collecting residual materialfrom the shoulders 30 into the recipient 40 while closing it.

FIG. 11 shows the arrangement of the separation units and the anodediscs 50. In FIG. 11A the recipients 40 are closed in order to press thecollected solid material out by moving the piston 20. In FIG. 11B therecipients are open and ready for collecting solid material from therotating anodes 50. In order to open or close the recipient 40 allrecipients 40 which are arranged next to anode discs 50 are connectedvia a connection bar 6. At their ends the connection bars 6 areconnected with the pneumatic cylinders 21 that are mounted onto theframe 5. The anode discs 50 are rotating vertically in the container 60.The anode discs 50 are fixed on a drive shaft 7 that is rotated by asingle drive 8 being mounted on a stationary table 9. The recipients canbe closed with the sliding carriage 10 comprising cover 11 andcomprising guiding rods 12.

FIG. 12 shows an electrophoresis cell with inlet 61 and overflow 62. Avertical rotating anode disc 50 rotates within a compartment of a multicompartment container 60. Slurry is filled in at the inlet openings 61and the dewatered slurry leaves the container via the overflow 62. It isintended to arrange the inlet openings 61 at the bottom of the container60 and the outlet 62 at the upper margin of the container 60.

It is possible to fill each compartment of a multi compartment container60 with fresh slurry by equally dividing the flow of fresh slurry. It isadvantageous that only one pump might be used for this way of filling anelectrophoresis cell. Another possibility is to fill a compartment withthe overflow slurry of the previous compartment, resulting in a solidcontent gradient in a row of compartments. It has to be noted that theformation of solid material on the anodes 50 stops below a solid contentof the slurry of about 9 to 10%, so that a slurry with a solid contentbelow this value might be supplemented with solid material from a bufferstorage or has to be removed from the process.

REFERENCE NUMBER LIST

-   -   5 frame    -   6 connecting bar    -   7 drive shaft    -   8 single drive    -   9 stationary table    -   10 sliding carriage    -   11 cover    -   12 guiding rod    -   20 piston    -   21 pneumatic cylinder    -   22 valve    -   30 shoulder    -   40 recipient    -   50 anode disc    -   60 container    -   61 inlet    -   62 overflow

The invention claimed is:
 1. A method for the concentration of a slurryof dispersed particles using a device with a supporting structureincluding modules received therein, the modules comprising: a. anelectrophoresis cell with at least one electrically connected cathode,and at least one electrically connected, rotatable anode disc, b. aseparation unit adjacent to each anode surface for receiving a cakematerial of dispersed particles, comprising a recipient and a pistonadapted to the recipient form, wherein the recipient has shouldersdimensioned to act as scraping flanges for taking off the cake materialfrom each anode, the piston is dimensioned for pressing the cakematerial out of the recipient, the separation unit has a slidingcarriage with a cover for closing the recipient and collecting residualcake material from the shoulders into the recipient while closing it,and the recipient has a half cylindrical form, the method comprising thefollowing steps: (i) introducing a slurry with dispersed particles inthe electrophoresis cell of the device; (ii) applying voltage to theresting electrodes of the electrophoresis cell; (iii) rotating eachanode a defined angle of rotation and stripping resting solid materialor cake into the recipient of the separation unit of the device; (iv)optionally closing the recipient with the sliding carriage; (v) pressingthe solid material or cake out of the separation unit with the piston;and (vi) optionally introducing fresh slurry into the electrophoresiscell via an inlet opening and removing excess slurry via an outlet ofeach cell and repeating steps (i) to (vi).
 2. The method according toclaim 1, wherein the recipient of the separation unit is closed with thesliding carriage after stripping the material or cake into it.
 3. Themethod according to claim 1, wherein the method is driven continuously,in intervals or by serial filling of each module.
 4. The methodaccording to claim 1, wherein the dispersed particles are mineralparticles.
 5. The method according to claim 4, wherein the slurry has amineral content of 10 to 50% by dry weight.
 6. The method according toclaim 1, wherein the dispersed particles are negatively charged.
 7. Themethod according to claim 1, wherein the dispersed particles areelectrically negatively-dispersed calcium carbonate.
 8. The methodaccording to claim 1, wherein a voltage of about 20 V is applied to theelectrodes.
 9. The method according to claim 1, wherein the angle ofrotation of each anode in the slurry is about 10°-15°.
 10. The methodaccording to claim 1, further comprising adjusting hoist time andinterval time to characteristics of the slurry.
 11. The method accordingto claim 1, wherein each anode disc is in contact with the slurry forabout 3 min.
 12. The method according to claim 1, wherein theelectrophoresis cell is a multiple compartment container.
 13. The methodaccording to claim 12, wherein the multiple compartment container ismade from an outer container shell with flanges fixed inside thecontainer to form the compartments.
 14. The method according to claim13, wherein the flanges are welded into the container shell.
 15. Themethod according to claim 12, wherein the multiple compartment containeris a single integral piece.
 16. The method according to claim 12,wherein the electrophoresis cell or multiple compartment container iselectrically isolated from all other components.
 17. The methodaccording to claim 12, wherein each anode disc is arranged verticallywithin the electrophoresis cell or compartments of the multiplecompartment container.
 18. The method according to claim 12, whereineach electrophoresis cell or compartment of the multiple compartmentcontainer has an inlet opening for the slurry at the bottom and anoverflow at the upper margin.
 19. The method according to claim 1,wherein each anode disc is mounted on a drive shaft for rotation. 20.The method according to claim 19, wherein each anode disc is fixed onthe drive shaft by a fixation flange, defining the distance between eachanode disc.
 21. The method according to claim 19, wherein jumper ringsare provided to electrically connect each anode.
 22. The methodaccording to claim 1, wherein the supporting structure is a frame madeof aluminium.
 23. The method according to claim 1, wherein each anodecomprises an anticorrosive coating.
 24. The method according to claim 1,wherein each anode comprises titanium.
 25. The method according to claim1, wherein each separation unit is made of synthetic material comprisingpoly-tetra-fluoroethylene (PTFE).
 26. The method according to claim 1,wherein the piston is driven pneumatically.